High-power five cylinder plunger pump

ABSTRACT

The present invention discloses a high-power five cylinder plunger pump. The high-power five cylinder plunger pump has a stroke of 10 inches, a cylinder spacing of 11.5 inches, and a braking power of 5000 HP. Beneficial effects: high power, large displacement; suitable for electric drive fracturing and turbine fracturing; an integral power end assembly or a split-type power end assembly could be selected according to specific operation conditions, thus better implementing the arrangement of fracturing units or fracturing vehicles; the dimension of the cylinder spacing ensures stable operations under a 5000 HP braking power with a long stroke.

TECHNICAL FIELD

The present invention relates to the technological field of plunger pump, and specifically relates to a high-power five cylinder plunger pump.

BACKGROUND

With the continuous development of ultrahigh-pressure, ultra-deep wells and horizontal wells in oil and gas fields, working conditions are becoming harsher. The fracturing equipment is required to operate with high pressure and large displacement, and some well sites also require continuous operations for a long period of time. Under a constant total pressure of a well site, the smaller the power displacement of a single fracturing equipment, the more fracturing equipment is needed to meet the demand of total pressure.

At present, the area of well sites for oil and gas production is required to be smaller and smaller, and reducing the number of fracturing equipment is one of the effective means. Actually, most accesses to well sites tend to be rugged, the more fracturing equipment, the more time is needed for the well site layout, which is time and labor consuming. Therefore, the smaler the power displacement of a single fracturing equipment, the greater the conflict with the area of the well site and the access to the well site. It is imminent to set a target of large operation in a small well site.

As the core component of fracturing equipment, the currently common plunger pumps on the market mainly include 2800 HP five cylinder plunger pump, 3000 HP three cylinder plunger pump, 3300 HP five cylinder plunger pump and 4000 HP three cylinder plunger pump; the 2800 HP five cylinder plunger pumps are mainly configured on Model 2500 fracturing equipment vehicle, (at present, Model 2500 fracturing vehicle is the most commonly used fracturing equipment in fracturing operations); the 4000 HP three cylinder plunger pump is configured on 3100 HP fracturing equipment vehicle, while 4000 HP plunger pump is a three cylinder pump, the displacement of which is much lower than that of 2800 HP five cylinder pump, only 82.54% of the displacement of 2800 HP five cylinder pump under the same plunger specification and the same stroke; for electric drive fracturing operations emerged in recent years, i.e., fracturing operations in which electric motors are used as the power source, electric motors with high power could be chosen, for example, the rated power can up to 3000 kW, 4000 kW, 5000 kW, 6000 kW, etc.; while there is no plunger pumps with such high specification, therefore, if the electric drive fracturing equipment is equipped with a 2800 HP plunger pump or a 4000 HP plunger pump, the advantages of electric drive fracturing would not be exhibited, comparable to driving a small vehicle with a high power.

Additionally, turbine fracturing is the recent development trend of fracturing operations (turbine fracturing is a fracturing operation mode in which a turbine engine is used as the power source), however, the output rotation direction of the turbine engine can not match with the input rotation direction of the current plunger pump. Therefore, a reversing mechanism is usually added before the input rotation direction of the plunger pump, thus causing an increase in the overall weight of the turbine fracturing equipment, and increasing the risk of failure and the maintenance cost, and the like.

Therefore, it is urgent to find a high-power, large-displacement plunger pump that can meet the requirements of different operating conditions and different fracturing operation modes.

SUMMARY

To overcome the deficiencies in the prior art, an objective of the present invention is to provide a high-power five cylinder plunger pump with a large displacement, which is suitable for electric drive fracturing and turbine fracturing; an integral power end assembly or a split-type power end assembly could be selected according to specific operation conditions, thus better implementing the arrangement of fracturing units or fracturing vehicles; the dimension of the cylinder spacing ensures stable operations under a 5000 HP braking power with a long stroke.

The objective of the present invention is achieved by the following technical measures: A high-power five cylinder plunger pump, the high-power five cylinder plunger pump has a stroke of 10 inches, a cylinder spacing of 11.5 inches, and a braking power of 5000 HP.

Further, the high-power five cylinder plunger pump comprises a power end assembly, a hydraulic end assembly and a reduction gearbox assembly, wherein the hydraulic end assembly and the reduction gearbox assembly are connected to the power end assembly respectively, the reduction gearbox assembly comprises a parallel reduction gearbox and a planetary reduction gearbox, one end of the planetary reduction gearbox is connected to the parallel reduction gearbox, and the other end of the planetary reduction gearbox is connected to the power end assembly.

Further, the reduction gearbox assembly has a reduction ratio of 12.2-12.5.

Further, the parallel reduction gearbox has a reduction ratio of 2.1-2.5, the planetary reduction gearbox has a reduction ratio of 5-5.8.

Further, the reduction ratio of the reduction gearbox assembly is suitable for fracturing operations with electric motors as the power source.

Further, the reduction gearbox assembly has a reduction ratio of 9.4-9.6.

Further, the parallel reduction gearbox has a reduction ratio of 1.6-1.8, the planetary reduction gearbox has a reduction ratio of 5.3-6.3.

Further, the reduction ratio of the reduction gearbox assembly is suitable for fracturing operations with turbine engines as the power source.

Further, the reduction gearbox assembly is arranged on the left or right end of the power end assembly according to the actual use requirements.

Further, when the high-power five cylinder plunger pump is used in fracturing operations with electric motors as the power source, the reduction gearbox assembly is arranged on the left or right end of the power end assembly, while when the high-power five cylinder plunger pump is used in fracturing operations with turbine engines as the power source, the reduction gearbox assembly is arranged on the right end of the power end assembly.

Further, an integral power end assembly or a split-type power end assembly is employed for the power end assembly according to the actual use requirements.

Further, the power end assembly comprises a power end housing, a crosshead supporting case and a holding frame which are arranged successively; for an integral power end assembly, the power end housing and the crosshead supporting case are in an integral construction, while for a split-type power end assembly, the power end housing and the crosshead supporting case are each in a separate structure, and the power end housing and the crosshead supporting case are fixed through bolts.

Compared with the prior art, the present invention has the following beneficial effects: a stroke of 10 inches ensures a large displacement, that is, ensures a high power, thus improving the operation efficiency. A cylinder spacing of 11.5 inches increases the bearing area of the connecting rod crosshead assembly (a connecting rod, a crosshead and a bearing bush), providing a sufficient bearing capacity for the five cylinder plunger pump of 5000 HP and ensuring a stable output of large displacement. The power increase of a five-cylinder plunger pump increases the fracturing capacity of a single fracturing equipment, enabling to reduce the total number of fracturing equipment in the well site, thus effectively resolving the contradiction between small area of the well site and more fracturing equipment, also completing the arrangement of the well site more quickly and less laboriously. The two transmission ratios solve the problem that there is no high-power plunger pump matched with the current high-power power source in electric drive fracturing and turbine fracturing, at the same time, different fracturing operation modes are adapted according to different transmission ratios to better match turbine engines and select the type of electric motors. Without adding a reversing mechanism, the biggest problem can be solved with the minimal cost, that is to say, the reduction gearbox assembly is arranged on the right end of the power end assembly, so that the output rotation direction of the turbine engine matches the input rotation direction of the crankshaft, so as to drive the five cylinder plunger pump in the turbine fracturing equipment without increasing the weight and without increasing the risk of failure and the maintenance cost. An integral power end assembly or a split-type power end assembly could be selected according to specific operation conditions, thus better implementing the arrangement of fracturing units or fracturing vehicles.

The present invention will be described in detail below with reference to the accompanying drawings and the detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a structural schematic diagram of the high-power five cylinder plunger pump (arranged at the right end).

FIG. 2 is a structural schematic diagram of the high-power five cylinder plunger pump (arranged at the left end).

FIG. 3 is a sectional view of the high-power five cylinder plunger pump.

FIG. 4 is a structural schematic diagram of a split-type power end assembly.

FIG. 5 is a structural schematic diagram of an integral power end assembly.

FIG. 6 is a structural schematic diagram of the connecting rod crosshead assembly.

FIG. 7 is a structural schematic diagram of the crankshaft.

FIG. 8 is a structural schematic diagram of the reduction gearbox assembly.

FIG. 9 is a structural schematic diagram of the parallel reduction gearbox.

FIG. 10 is a structural schematic diagram of the planetary reduction gearbox.

Wherein, 1. power end assembly, 2. hydraulic end assembly, 3. reduction gearbox assembly, 4. input flange, 5. power end housing, 6. bearing, 7. crankshaft, 8. connecting rod crosshead assembly, 9. axle journal, 10. bellcrank, 11. plunger, 12. valve housing, 13. crosshead supporting case, 14. holding frame, 15. connecting bolt, 16. parallel reduction gearbox, 17. planetary reduction gearbox, 18. bull gear, 19. pinion, 20. planetary gear, 21. gear ring, 22. sun gear.

DESCRIPTION OF THE EMBODIMENTS

As shown in FIGS. 1 to 10, the present invention provides a high-power five cylinder plunger pump. The high-power five cylinder plunger pump has a stroke of 10 inches, a cylinder spacing of 11.5 inches, and a braking power of 5000 HP. The stroke of 10 inches ensures a large displacement, that is, ensures a high power, thus improving the operation efficiency. A cylinder spacing of 11.5 inches increases the bearing area of the connecting rod crosshead assembly 8 (a connecting rod, a crosshead and a bearing bush), providing a sufficient bearing capacity for the five cylinder plunger pump of 5000 HP and ensuring a stable output of large displacement. The power increase of a five-cylinder plunger pump increases the fracturing capacity of a single fracturing equipment, enabling to reduce the total number of fracturing equipment in the well site, thus effectively resolving the contradiction between small area of the well site and more fracturing equipment, also completing the arrangement of the well site more quickly and less laboriously.

The high-power five cylinder plunger pump comprises a power end assembly 1, a hydraulic end assembly 2 and a reduction gearbox assembly 3, wherein the hydraulic end assembly 2 and reduction gearbox assembly 3 are connected to the power end assembly 1 respectively, the hydraulic end assembly 2 is connected to the power end assembly 1 through a connecting bolt 15; the reduction gearbox assembly 3 is connected to the power end assembly 1 throught a bolt; an input flange 4 is disposed outside the reduction gearbox assembly 3, and the reduction gearbox assembly 3 is connected to a power source through the input flange 4. The reduction gearbox assembly 3 comprises a parallel reduction gearbox 16 and a planetary reduction gearbox 17, one end of the planetary reduction gearbox 17 is connected to the parallel reduction gearbox 16, and the other end of the planetary reduction gearbox 17 is connected to the power end assembly 1. The input angle of the reduction gearbox assembly 3 can be adjusted according to input requirements, thereby satisfying the multi-angle adjustment required for the transmission of the five cylinder plunger pump in the fracturing equipment. The reduction gearbox assembly 3 is meshed with bevel gears. The planetary reduction gearbox 17 comprises one sun gear 22, four planetary gears 20 and one gear ring 21. The four planetary gears 20 constitutes a planetary gear mechanism, which is located in the interior of the gear ring 21, and the sun gear 22 is located at the center of the planetary gear mechanism. The parallel reduction gearbox 16 comprises a bull gear 18 and a pinion 19. The pinion 19 is connected to the input flange 4, and the bull gear 18 is connected to the sun gear 22 of the planetary reduction gearbox 17 coaxially. The rotational speed is input through the input flange 4, and transferred to the bull gear 18 through the pinion 19 to achieve the first-stage reduction, and the reduced speed is transferred to the sun gear 22 through the bull gear 18 and then transferred to the planetary gears 20 through the sun gear 22 to achieve the second-stage reduction, thereby obtaining a large transmission ratio. The hydraulic end assembly 2 comprises a valve housing 12 and a plunger 11, the plunger 11 is located in the interior of the valve housing 12.

The reduction gearbox assembly 3 has a reduction ratio of 12.2-12.5. The parallel reduction gearbox 16 has a reduction ratio of 2.1-2.5, and the planetary reduction gearbox 17 has a reduction ratio of 5-5.8. The reduction ratio of the reduction gearbox assembly 3 is suitable for fracturing operations with electric motors as the power source, that is electric drive fracturing. The reduction gearbox assembly 3 has a reduction ratio of 9.4-9.6. The parallel reduction gearbox 16 has a reduction ratio of 1.6-1.8, and the planetary reduction gearbox 17 has a reduction ratio of 5.3-6.3. The reduction ratio of the reduction gearbox assembly 3 is suitable for fracturing operations with turbine engines as the power source, that is turbine fracturing. The two transmission ratios solve the problem that there is no high-power plunger pump matched with the current high-power power source in electric drive fracturing and turbine fracturing, at the same time, different fracturing operation modes are adapted according to different transmission ratios to better match turbine engines and select the type of electric motors.

By setting different reduction ratios, the applicability of the 5000 HP high-power five cylinder plunger pump is increased, which is applicable to both electric drive fracturing operations and turbine fracturing operations. The output displacements of single electric drive fracturing equipment and single turbine fracturing equipment are increased to better solve the technical problem that a small well site is not enough for large operations.

The reduction gearbox assembly 3 is arranged on the left or right end of the power end assembly 1 according to the actual use requirements. Compared with the current five cylinder plunger pump, a right-end connection mode is added, that is, the reduction gearbox assembly 3 is connected to the right end of the crankshaft 7 in the power end assembly 1.

When the high-power five cylinder plunger pump is used in fracturing operations with electric motors as the power source, the reduction gearbox assembly 3 is arranged on the left or right end of the power end assembly 1. The output rotation direction of the electric motor is adjustable, therefore, no matter the reduction gearbox assembly 3 is arranged on the left or right end of the power end assembly 1, the output rotation direction of the electric motor could be adjusted according to the requirement of the input rotation direction of the crankshaft 7. When the high-power five cylinder plunger pump is used in fracturing operations with turbine engines as the power source, the reduction gearbox assembly 3 is arranged on the right end of the power end assembly 1. Without adding a reversing mechanism, the biggest problem can be solved with the minimal cost, that is to say, the reduction gearbox assembly 3 is arranged on the right end of the power end assembly 1, so that the output rotation direction of the turbine engine matches the input rotation direction of the crankshaft 7, so as to drive the five cylinder plunger pump in the turbine fracturing equipment without increasing the weight and without increasing the risk of failure and the maintenance cost.

An integral power end assembly 1 or a split-type power end assembly 1 can be employed for the power end assembly 1 according to the actual use requirements. The integral power end assembly 1 is suitable for continuous fracturing operation under high pressure in a well site and suitable for whole skid installation arrangement due to its high stiffness, strong bearing capacity and stable structure. The split-type power end assembly 1 is lighter than the integral power end assembly 1, so it is suitable for intermittent fracturing operation in a well site, and can also provide more carrying ways for fracturing equipment, such as vehicle-loaded, semi-trailer, skid-mounted, and the like. This two kinds of power end assembly 1 can better meet the different operation requirements and delivery requirements of the site.

The power end assembly 1 comprises a power end housing 5, a crosshead supporting case 13 and a holding frame 14 which are arranged successively; for an integral power end assembly 1, the power end housing 5 and the crosshead supporting case 13 are in an integral construction, while for a split-type power end assembly 1, the power end housing 5 and the crosshead supporting case 13 are each in a separate structure, and the power end housing 5 and the crosshead supporting case 13 are fixed through bolts. A crankshaft assembly is located in the interior of the power end housing 5, and a connecting rod crosshead assembly 8 is located in the interior of the crosshead supporting case 13. The crankshaft assembly is connected to one end of the connecting rod crosshead assembly 8, and the other end of the connecting rod crosshead assembly 8 drives the plunger 11 through the transmission of a pull rod to reciprocate in the valve housing 12, thereby achieving the suction of low pressure liquid and the discharge of high pressure liquid. The crankshaft assembly comprises a crankshaft 7 and a bearing 6, the crankshaft 7 is connected to the power end housing 5 through the bearing 6. The crankshaft 7 comprises six axle journals 9 and five bellcranks 10, one bellcrank 10 is disposed between every two adjacent axle journals 9, and the distance between the center of rotation of the bellcrank 10 and the center of rotation of the crankshaft 7 is 5 inches, and the bearing 6 is a cylindrical roller bearing.

It will be appreciated to persons skilled in the art that the present invention is not limited to the foregoing embodiments, which together with the context described in the specification are only used to illustrate the principle of the present invention. Various changes and improvements may be made to the present invention without departing from the spirit and scope of the present invention. All these changes and improvements shall fall within the protection scope of the present invention, which is defined by the appended claims and equivalents thereof. 

1. A five cylinder plunger pump, wherein the five cylinder plunger pump has a stroke of 10 inches for each plunger, a cylinder spacing of 11.5 inches, and a brake horsepower of 5000 HP; the five cylinder plunger pump can be applied in both fracturing operations with an electric motor as a power source and fracturing operations with a turbine engine as a power source.
 2. The five cylinder plunger pump according to claim 1, wherein the five cylinder plunger pump comprises a power end assembly, a hydraulic end assembly and a reduction gearbox assembly; the hydraulic end assembly and the reduction gearbox assembly are connected to the power end assembly respectively; the reduction gearbox assembly comprises a parallel reduction gearbox and a planetary reduction gearbox, one end of the planetary reduction gearbox is connected to the parallel reduction gearbox, the other end of the planetary reduction gearbox is connected to the power end assembly.
 3. The five cylinder plunger pump according to claim 2, wherein the reduction gearbox assembly has a reduction ratio of 12.2-12.5.
 4. The five cylinder plunger pump according to claim 3, wherein the parallel reduction gearbox has a reduction ratio of 2.1-2.5, the planetary reduction gearbox has a reduction ratio of 5-5.8.
 5. (canceled)
 6. (canceled)
 7. The five cylinder plunger pump according to claim 2, wherein the reduction gearbox assembly has a reduction ratio of 9.4-9.6.
 8. The five cylinder plunger pump according to claim 7, wherein the parallel reduction gearbox has a reduction ratio of 1.6-1.8, the planetary reduction gearbox has a reduction ratio of 5.3-6.3.
 9. (canceled)
 10. (canceled)
 11. The five cylinder plunger pump according to claim 1, wherein the reduction gearbox assembly is arranged on either of the left end or the right end of the power end assembly.
 12. (canceled)
 13. (canceled)
 14. The five cylinder plunger pump according to claim 1, wherein the power end assembly comprises a power end housing, a crosshead supporting case and a holding frame which are arranged successively; the power end housing and the crosshead supporting case can be arranged as a whole or independently. 